3D Printing Method for Complex Overhangs via Thermal Deformation
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Solution Overview
Problem
Current 3D printing methods, such as FDM, face challenges in printing complex shapes with overhangs and multiple areas protruding beyond a certain distance, leading to time-consuming and costly processes with lower quality due to frequent interruptions and difficulties in creating apertures.
Innovation Solution
A method involving printing a 3D structure in a first plane, cooling, heating specific surfaces to soften the material, and deforming it into a second plane to achieve the desired shape, allowing for the creation of complex articles with snap-fit locking devices and apertures efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional FDM printing is used for complex shapes with overhangs, then the printing process becomes time-consuming and costly, but the quality and reliability of the printed product deteriorates due to frequent interruptions
Solution Approach 1:
The printing process is divided into two distinct phases: a first printing phase that creates a simplified 3D structure with features in a first plane, and a second printing phase that adds complex overhangs and features in a second plane. This segmentation allows each phase to be optimized independently, maintaining print quality while enabling complex geometries that would otherwise require frequent interruptions.
Solution Approach 2:
The method performs preliminary printing of a simplified structure before adding complex features. By first creating the basic 3D structure with features in the first plane and allowing it to cool and solidify, the printer can then add overhangs and complex features in the second plane without compromising the structural integrity or requiring frequent interruptions.
2Ease of manufacture
If printing starts in an X-Y plane with continuous lines, then the product structure is strong and easy to print, but the ability to create features in Z-plane beyond a certain distance deteriorates
Solution Approach 1:
The method transitions from printing only in the X-Y plane to printing in both the X-Y plane and the Z-plane. The first printing phase creates the base structure in the X-Y plane, while the second printing phase adds features extending into the Z-plane with overhangs. This dimensional transition enables complex 3D features while maintaining the simplicity of continuous line printing in each phase.
3Adaptability or versatility
If overhang printing is performed with careful tuning of speed and temperature, then the overhang parts can be printed, but the process becomes complex and time-consuming
Solution Approach 1:
The overhang printing process is segmented into two distinct phases: a first printing phase that creates the base structure without overhangs, and a second printing phase that adds overhangs and complex features. Each phase has optimized parameters for its specific requirements, reducing overall process complexity while enabling overhang printing capability.
Solution Approach 2:
The method performs preliminary printing of the base structure before adding overhangs. By first creating the simplified 3D structure and allowing it to cool and solidify, the printer can then add overhangs with optimized parameters without the complexity of trying to print overhangs continuously throughout the entire process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables fast and cost-effective printing of complex 3D articles by rearranging the printed structure into the desired shape, overcoming limitations of conventional methods and improving print quality.
Implementation Method 1
heating the one of the first and the second surfaces of the 3D structure
Implementation Method 2
cooling the 3D structure
Implementation Method 3
deforming the 3D structure in a second plane deviating from the first plane
Data Source
AI summary
The present invention relates to a method for manufacturing a 3D article (1) by means of 3D printing, the method comprising the steps of: a) printing a 3D structure (1′) extending in a first plane and comprising a first surface (4) and a second surface (4′) being opposite to the first surface (4); b) cooling the 3D structure (1′); c) heating the one of the first and the second surfaces (4, 4′) of the 3D structure (1′); d) deforming the 3D structure (1′) in a second plane deviating from the first plane, such that a 3D article (1) is obtained; c) cooling the 3D article (1).